Ford 2005 E-Series Incomplete Vehicle Manual Download Page 21

E-SERIES 

(May, 2004)

18

E-SERIES 

(May, 2004)

19

STATEMENTS OF CONFORMITY

108  The statements below are applicable to the following 

incomplete vehicle type:

•  E-Series Basic (Stripped) Chassis:

Conformity  with  Standard  108,  Lamps,  Reflective 

Devices, and Associated Equipment, is not substantially 

affected  by  the  design  of  this  incomplete  vehicle; 

accordingly,  Ford  Motor  Company  makes  no  rep-

resentation as to conformity with this standard. However, 

Ford Motor Company does represent that the items 

of lighting equipment, when provided in the E-Series 

dunnage box attached to the chassis, are designed to 

conform to the requirements of Standard 108.

108  Canadian Requirements:

The  preceding  statements  for  Standard  108  are 

appropriate compliance representations for CMVSS 

108, Lighting, and CMVSS 108.1, Headlamps, if this 

vehicle  is  manufactured  for  sale  or  use  in  Canada, 

provided:

•  No component of the Daytime Running Lamp (DRL) 

system is removed, relocated, or modified.

110  U.S. Requirements:
 

The statement below is applicable to all incomplete 

vehicles with a GVWR of 4536 kg [10,000 lbs] or 

less:

This incomplete vehicle does not comply to FMVSS 

110. In order to comply, the final stage manufacturer 

must affix a tire placard as specified in paragraph S4.3 

of FMVSS 110. The decal must be affixed to the B-Pillar. 

See below for placard content and note color and format 

requirements in S4.3.

108 

(Continued)

111  The statements below are applicable to the incomplete 

E-Series Van with no driver-seat when equipped with 

a convex mirror on the passenger-side:

This vehicle, when completed, will conform to Standard 

111, Rearview Mirrors, if:

•  The mirrors and their mounts as supplied by Ford 

Motor Company, are not removed, relocated, replaced, 

or altered.

•  No  structural modifications  are  made  to  the  body 

which would affect the stability of the mirror mounts.

•  The  Seating  Reference  Point  (see  definition  on           

page 5) and the seat back torso angle of the driver-

seat installed or completed by the subsequent stage 

manufacturer  are  located  as  shown  in  Figure  C           

page 32 corresponding to the particular incomplete 

vehicle type.

•  Any modifications or additions made to this incomplete 

vehicle do not adversely affect the driver’s view to 

the rear in the outside mirrors along both sides of 

the vehicle.

If any alteration blocks the rear field of view through the 

inside mirror, Standard 111 may require that the vehicle 

have a flat glass on the passenger side.

111  The statement below is applicable to the following 

incomplete vehicle types when not equipped with 

outside mirrors:

•  Cutaway
•  E-Series Basic (Stripped) Chassis
•  Incomplete E-Series Van

Conformity with Standard 111, Rearview Mirrors, is not 

substantially affected by the design of this incomplete 

vehicle; accordingly, Ford Motor Company makes no 

representation as to conformity with this Standard.

111  The statements below are applicable to the Cutaway 

when equipped with outside mirrors:

Conformity with the stability requirements of Standard 

111,  Rearview  Mirrors,  is  not  substantially  affected 

by the design of this incomplete vehicle; accordingly 

Ford Motor Company makes no representation as to 

conformity with stability requirements of this Standard. 

However,  except  for  the  stability  requirement,  this 

vehicle, when completed, will conform to Standard 111, 

Rearview Mirrors, if:

•  The outside mirrors and their mounts, as supplied 

by Ford Motor Company, are installed in accordance 

with the instructions that accompany them and they 

are not relocated, replaced, or altered.

•  The Cutaway with the School Bus Prep Package is 

completed as a school bus and any outside mirrors 

(not provided by Ford Motor Company) are installed 

in conformity with the requirements of Standard 111 

for school buses.

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111  The statements below are applicable to the following 

incomplete vehicle types when equipped with a driver 

seat (including untrimmed seat) and a convex mirror 

on the passenger-side:

•  Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 

111, Rearview Mirrors, if:

•  The mirrors and their mounts as supplied by Ford 

Motor Company are not removed, relocated, replaced, 

or altered, except as noted below.

•  No  structural modifications  are  made  to  the  body 

which would affect the stability of the mirror mounts.

•  Any modifications or additions made to this incomplete 

vehicle do not adversely affect the driver’s view to 

the rear in the outside mirrors along both sides of 

the vehicle.

•  The driver-seat is not replaced, relocated, or modified 

other than for the addition of seat trim.

If any alteration blocks the rear field of view through the 

inside mirror, Standard 111 may require that the vehicle 

have a flat glass mirror on the passenger side.

Summary of Contents for 2005 E-Series

Page 1: ...KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER 2005 E SERIES INCOMPLETE VEHICLE MANUAL May 2004 5C2S 19A268 AA Incomplete Vehicle Types For This Manual INCOMPLETE E SERIES VANS W...

Page 2: ...X X X X X X 124 Accelerator Control Systems X X X X X 131 School Bus Pedestrian Safety Devices except Multifunction School Activity Bus X 135 Light Vehicle Brake Systems X 10 X 10 X 10 X 10 X 10 201 O...

Page 3: ...of 4536 kg 10 000 lb or less and an unloaded vehicle weight of 2495 kg 5500 lb or less 4 Applicable to vehicles with a GVWR of 2722 kg 6000 lb or less 5 Injury criteria required for vehicles with a G...

Page 4: ...nder the headings Unleaded Gasoline Label page 49 Warranty and Maintenance page 50 and Emission Control Information Label page 50 It is the responsibility of the final stage manufacturer to determine...

Page 5: ...Vehicles MDPV 49 Frontal Area and Weight Restrictions 49 High Altitude Requirements 49 Emission Control Hardware 49 Unleaded Gasoline Label 49 Exterior Noise 50 Tampering with Noise Controls 50 Warra...

Page 6: ...ab cut out for the intended installation of a structure that permits access from the driver s area to the back of the completed vehicle Ford Motor Company Cutaway Chassis Canada an incomplete vehicle...

Page 7: ...ada the unique Design H point as defined in section 2 2 11 1 of SAE Recommended Practice J1100 June 1993 that a establishes the rearmost normal design driving or riding position of each designated sea...

Page 8: ...l Regulations Vehicles Manufactured in Two or More Stages Part 568 specifies that final stage manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standa...

Page 9: ...requirements The Canadian Motor Vehicle Safety Act and Regulations require installation of an incomplete vehicle certification label with the National Safety mark on it on vehicles manufactured for s...

Page 10: ...5 COMPLETED VEHICLE TYPES COMPLETED VEHICLE TYPES IMPORTANT Ford Motor Company makes no representation that the completed vehicle types listed above are the only vehicle types appropriate for the inc...

Page 11: ...Cutaway This vehicle when completed will conform to Standard 101 Controls and Displays if The controls displays and their identifications supplied by Ford Motor Company are not removed relocated alter...

Page 12: ...s added to this vehicle it must conform to the requirements of this Standard 1 Route the cable after the instrument cluster is installed in the vehicle Do not kink the cable Do not bend the cable to a...

Page 13: ...he Ford Source Book See your local Ford Dealer and refer to appropriate model year and specific vehicle for required information Abbreviation definitions and a vehicle diagram to assist with the equat...

Page 14: ...front seats and forward of the centerline of the rear axle Do not restrict the E Series seat travel and provide seatback clearance to obtain the torso angle as shown in Figure C page 32 The horizontal...

Page 15: ...ound in Table B page 15 The maximum GAWRs and GVWR as identified on the cover of this document are not exceeded with the vehicle weight at Unloaded Vehicle Weight Passenger Load P See E Series Passeng...

Page 16: ...Weight at the rear wheels of the vehicle chassis and cab fuel tanks full pounds Including option weight Wc Weight of the vehicle chassis and cab fuel tanks full pounds Including option weight WB Vehic...

Page 17: ...0 E 350 Basic Stripped Chassis DRW 4013 158 3946 8700 E 350 Basic Stripped Chassis DRW 4470 176 3946 8700 1 2767 kg 6100 lb When completed with 6 or less designated seating positions 2 Maximum unloade...

Page 18: ...e the CGh of the vehicle from Equation B into the appropriate equations below to determine the allowable range of the CGv If the actual CGv from Equation A is within the range calculated the center of...

Page 19: ...es vehicles will meet the FMVSS 108 requirement for DRL s when DRL s are provided Conformity with Standard 108 S 12 Headlamp Concealment Devices are not substantially affected by the design of this in...

Page 20: ...The statements below are applicable to the following incomplete vehicle types Incomplete E Series Van or Wagon This vehicle when completed will conform to Standard 108 Lamps Reflective Devices and Ass...

Page 21: ...of the vehicle If any alteration blocks the rear field of view through the inside mirror Standard 111 may require that the vehicle have a flat glass on the passenger side 111 The statement below is a...

Page 22: ...eplaced conforms to the DOT 3 specifications of the standard and contaminants are not introduced into the hydraulic brake system 118 The statement below is applicable to all incomplete vehicle types n...

Page 23: ...hassis component is accompanied by the addition of equal weight The maximum GAWRs and GVWR as identified on the cover of this document are not exceeded with the vehicle weight at Unloaded Vehicle Weig...

Page 24: ...ment below is applicable to the following incomplete vehicle type if the GVWR is 4536 kg 10 000 lb or less E Series Basic Stripped Chassis Conformity with Standard 201 Occupant Protection in Interior...

Page 25: ...igned by Ford Motor Company to be completed as a walk in van type vehicle Walk in vans are exempt from the impact requirements of Standard 203 Impact Protection for the Driver from the Steering Contro...

Page 26: ...of this incomplete vehicle accordingly Ford Motor Company makes no representation as to conformity with this Standard 207 208 209 and 210 INFORMATION For additional information to assist in designing...

Page 27: ...any makes no representation as to conformity with this Standard 207 The statements below are applicable to the following incomplete vehicle types with no front seats Incomplete E Series Van Cutaway E...

Page 28: ...ion 4 5 1 c of Standard 208 No alteration or modifications are made to the body chassis including front bumper drivetrain body mounts or front suspension from the B pillar forward Any front overhead c...

Page 29: ...ted by an occupant Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard 208 Continued 208 The statements below are applicable to the incomplete E...

Page 30: ...to the body chassis including front bumper drivetrain body mounts or front suspension from the B pillar forward Any front overhead console installed on an Incomplete E Series is configured as follows...

Page 31: ...r Bag Supplemental Restraint System Information Labels are not affixed to the front visors but shipped in dunnage the following is necessary to meet Standard 208 The information label must be permanen...

Page 32: ...NEL ASY COVER ALL WAGON VAN MODELS ONLY PASSENGER SEAT RIGHT HAND INSTALLATION ALL CUTAWAY MODELS ONLY 29 5 4 ft lb 35 5 ft lb 40 0 6 0 Nm 29 5 4 ft lb PIA BOLT TORQUE 47 5 7 2 Nm 35 5 ft lb PIA BOLT...

Page 33: ...DR 571479 PASS R H TRACK N011488 S424 STUD 2 REQ D XC25 1560094 A MANUAL SUPPORT ASY COVER FRT ST PVT PIA BOLT TORQUE 40 0 6 0 Nm W705944 S424 SCREW 2 REQ D 55 0 8 3 Nm F7U S14A699DB WIRE ASY 2C24 156...

Page 34: ...POINT A D A F C DIMENSIONS ARE INCHES E E POINT A POINT A DRIVER SEAT PASSENGER SEAT C L VEHICLE B B DRIVER SIDE ONLY TORSO ANGLE 18 DRIVER 21 PASSENGER SEAT BASE SEAT BASE C L OUTSIDE FRONT FASTENER...

Page 35: ...48 S190 SCREW TORQUE 12 0 1 8 Nm 9 1 3 ft lb 14B321 A SNS BRKT ASY A BAG FRT FIGURE E2 E SERIES RESTRAINT CONTROL MODULE FIGURE E3 E SERIES RESTRAINT CONTROL MODULE Sensor system also connected to pyr...

Page 36: ...T OF VEHICLE NOTE SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY THE SPOTWELDS X IN THIS AREA MUST REMAIN INT...

Page 37: ...AXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY DIMENSIONS ARE IN INCHES CUTLINE SECTION EE SECTION FF CUTLINE SECTION GG CUTLINE 533...

Page 38: ...LS DIMENSIONS ARE INCHES C L OUTER EDGE OF TROUGH REGULAR VAN B PILLAR REINFORCEMENT WINDSHIELD HEADER FORWARD CUT LINE 50 8 2 00 SECTION AT C L OF ROOF HEADLINER PLANE FOR VEHICLES NOT EQUIPPED WITH...

Page 39: ...se in Canada In such a case CMVSS 209 paragraphs 2 and 3 4 and 5 14 15 and 7 are substituted for the reference to FMVSS 209 Sections 4 1 b c e g and h respectively 210 The statements below are applica...

Page 40: ...9 statements that follow include any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer as well as the basic body or body structure 212 INFORM...

Page 41: ...equipped with a driver side door only when completed will conform to Standard 214 Side Impact Protection for that door only if no alterations modifications or replacements are made to the door surroun...

Page 42: ...applicable to the Cutaway equipped with the School Bus Prep Package when completed as a school bus Conformity with Standard 222 School Bus Passenger Seating and Crash Protection is not substantially a...

Page 43: ...nstrate compliance with FMVSS 301 are loaded pursuant to S7 1 6 of the Standard The test weights of these vehicles comprise the Unloaded Vehicle Weights including the weights of all available regular...

Page 44: ...on Package E Series Cutaway SRW with Gasoline Engine and School Bus Preparation Package This vehicle when completed will conform to Standard 301 Fuel System Integrity if The following fuel system comp...

Page 45: ...licable provisions of Standard 301 301 The statements below are applicable to the following incomplete vehicle type if the GVWR Is 4536 kg 10 000 lb or less E Series Basic Stripped Chassis Conformity...

Page 46: ...ts must be securely retained to remain intact when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301 The Basic Stripped Chassis is equipped with a Fuel S...

Page 47: ...rers meet the flammability requirements of the Standard 302 The statement below is applicable to the following incomplete vehicle type E Series Basic Stripped Chassis Conformity with Standard 302 Flam...

Page 48: ...mm 0 075 14 GA HRLC STEEL 2 8 GUSSET CROSS SILL TO OUTER SUPPORT L H 1 9mm 0 075 14 GA HRLC STEEL 4 9 GUSSET CROSS SILL TO OUTER SUPPORT R H 1 9mm 0 075 14 GA HRLC STEEL 4 10 SUPPORT CROSS SILL OUTER...

Page 49: ...0 3 86 26 9 1 06 C L 4 C L C L 38 6 1 52 34 9 1 37 110 0 4 33 18 0 0 71 48 0 1 89 122 0 4 80 170 0 6 69 40 3 1 59 172 0 6 77 138 8 5 46 32 6 1 28 71 6 3 13 36 1 1 42 42 7 1 68 425 8 16 76 134 0 5 28 8...

Page 50: ...because Ford Motor Company has no control over how this incomplete vehicle is completed by subsequent stage manufacturers Ford Motor Company does not represent that the completed vehicle incorporatin...

Page 51: ...partment Incomplete vehicles with engines certified using heavy duty engine protocol are not limited by weight and frontal area restriction for exhaust emissions It is important that the final stage m...

Page 52: ...a Air Resources Board Production fuel systems supplied on incomplete 2005 model year trucks manufactured by Ford Motor Company comply with these requirements If the subsequent stage manufacturer adds...

Page 53: ...ol Label specifications for VIN label is not substantially affected by the design of this incomplete vehicle Accordingly Ford Motor Company makes no representation as to conformity with this requireme...

Page 54: ...E SERIES May 2004 52 SUPPLEMENTS...

Page 55: ...ed to 734 713 2971 Canadian orders should be faxed to 905 670 0844 FORD SERVICE PUBLICATIONS Many Ford Service Publications pertain to a specific Model Year and vehicle types The following publication...

Page 56: ...FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE ONTARIO L6J 5E4...

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